improving quality & profits with vision
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April 2014
Tim Seymour
Vision Application Specialist, SICK Australia
: Improving Quality & Profits with Machine Vision
: SICK AG 2
Machine Vision Systems Contents
: What is Machine vision?
: When do we use it?
: What types of Cameras can be used in Industry
: Examples of Vision Solutions
: SICK AG
Machine Vision Systems
: When do we use it?
: The benefits of Machine Vision are;
: $$$$$$$$
- Improving quality of the finished product
- Simplifying, improving or increasing work flow,
- Reducing waste , both in materials and effort.
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: SICK AG
Machine Vision Systems
: What is Machine Vision?
: Use of cameras in the context of process control
: Is defined as the analysis of images and extraction of data for controlling an
automated process or action
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Image capture
Image analysis
Decision making
Data output
Repeat process
: SICK AG
What is Machine Vision
: Image capture
: 1 D, 2 D or 3 Dimensions ?
: Illuminating an Object and acquiring an image
- Front or back light?
- Visible or Infra Red?
: Moving or stationary ?
: Triggered or Free running?
5
Image captur
e
Image analy
sis
Decision
making
Data output
Repeat
process
: SICK AG
Image analysis
: to answer the following questions in highly repetitive situations....
Tim Seymour April 2014 6
Good/bad
Classification Position Identification Dimension
OK? Where? What does it say? How large?
: SICK AG
Decision Making and Data output
: What results do you need?
- Pass or Fail?
- Sort?
- Digital or Serial?
- Settings Adjustable or fixed?
: How much time do you have?
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Image capture
Image analysis
Decision making
Data output
Repeat process
: SICK AG
Types of Machine Vision Components
: Vision ”Sensors”
- Easy to use
- Application-specific, or configurable but limited
- Works stand-alone
: ”Smart” camera
- Flexible, programmable with ready-to-use
toolbox
- Works stand-alone, no PC
: PC-based camera ”components”
- Fully flexible, programmable with low-level
languages (C++, .NET, etc)
- The camera only takes images, the PC
analyzes and controls the process using a
visual studio software package.
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Vision sensor or
smart camera
PC-based
: SICK AG
Some terms explained…
: What is a pixel?
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Pixel
: SICK AG
Some terms explained…
: FOV?
▪ Field of View;
: ROI?
▪ region of interest….?
: TOF?
▪ Time of Flight
: OCR
▪ Optical character recognition
: RGB
▪ Colour cameras
: IR or UV
▪ Type of light emitted or received?
: GUI
▪ Graphical User Interface that appears on the Human Machine Interface
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: SICK AG
Simple Vision Sensors
: Just connect and align
- Easy to use
- Single purpose
- No parameters
- No Logic
: Examples are
- X,Y positioners
- Shingle counters
- Registration detectors
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: SICK AG
Simple solutions using smart sensors
: object counters
: how many containers can I fit on a conveyor?
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: SICK AG
Simple solutions using smart sensors
: X,Y positioners
: the challenge is to align the pallet
handling system to the shelf or bay
location.
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: SICK AG
Simple solutions using smart sensors
: Labels without marks kept in register
: The saving may only be 2%.... However…...
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: SICK AG
Complex Vision Sensors
: The Features of a Complex Vision Sensor include;
- Around 10 to 20 Algorithms or Vision ”tools”
- Ethernet or USB connectivity
- Simple logic functions
- Discrete outputs
- Fast processing times
- Low to medium image resolution
- Integrated light sources
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: SICK AG
Example Applications…
: Interactive Edge Guiding on carpet
gluing line; 2 x cameras for 2 different
materials running simultaneously.
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: SICK AG
Example Applications for Vision sensors…
: APPLICATION; Ultra Violet Light source to inspect a optically challenging product
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: SICK AG
Example Applications for Vision sensors…
: APPLICATION;
- Look for correct insertion of wafer in packaging, before dosing of ice cream
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: SICK AG
Example Applications for Vision Sensors…
: APPLICATION: Cheese Sticks
: Formation checks
:
: TECHNOLOGY: 2D Vision Camera
: LED Diffuse Back light
:
: METHODOLOGY: Back Lit image for Length and shape check
:
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Courtesy of
: SICK AG
“Smart” Vision Cameras
: The Features of a Smart Camera are;
- Around 200 Algorithms and logical processes
- Ethernet connectivity
- Complex logical and mathematical functions
- Multiple outputs
- Fast processing times
- Medium to high image resolution
- Usually 2D ( some 3D)
- Multiple lens options
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: SICK AG
Example Applications for Smart Cameras…
: APPLICATION: Glass Bottle Rim & Neck validation
: Break, crack & foreign matter detection
:
: TECHNOLOGY: 2D Vision system with PLC control for ejection
: LED illumination, Operator HMI for sensitivity adjustment
:
: METHODOLOGY: Front Lit image
: Greyscale value mapping.
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Courtesy of
: SICK AG
Example Applications for Smart Cameras…
: APPLICATION: Frozen Pie packets
: Packet formation & closure verification
:
: TECHNOLOGY: 2D Vision system
: LED illumination,
:
: METHODOLOGY: Back Lit image to silhouette packet to confirm edge formation
:
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Courtesy of
: SICK AG
Example Applications for Smart Cameras…
: APPLICATION: Sanitary pads;
: Pad thickness, feature presence & location
:
: TECHNOLOGY: “Linescan” smart cameras
: LED illumination, Operator HMI for sensitivity adjustment
:
: METHODOLOGY: Silhouetted image
: Greyscale value mapping and measurement,
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Courtesy of
: SICK AG
Example Applications for Smart Cameras…
: APPLICATION: Lid & tub label validation
: Correct ID & position, Internal tub defect detection
:
: TECHNOLOGY: 2D smart cameras with bar code reading tools
: LED illumination, Operator HMI
:
: METHODOLOGY: Front lit image
: Greyscale; 2D Code reader & Pattern match.
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Courtesy of
: SICK AG
Camera Components
: High end Camera components;
- High resolution, 1, 2, & 3D
- Special Intefaces
▪ GigE, Camera Link, Firewire, etc
- Most analysis functions completed by seperate software in an external PC
- Fast imaging times
- Usually high image resolutions
- Multiple lens options
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: SICK AG
Camera Components used with 3rd party software
: APPLICATION: Batch Mixing Verification;
: Scanning Powdered Ingredients Bags
:
: TECHNOLOGY: 2D camera
: LED illumination, Operator HMI
:
: METHODOLOGY: Front lighted image,
: Intuitive pattern matching linked to customer data base for
ingredient lists and quantities.
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Courtesy of
: SICK AG
Camera Components used with 3rd party software
: APPLICATION: Detect “Off Centre Core”;
: “News Print” Paper rolls
:
: TECHNOLOGY: Hi res 2D camera
: Infra Red LED illumination, Operator HMI
:
: METHODOLOGY: Front lighted image,
: edge detection followed by mathematically calculations to
determine centre of roll vs centre of core. .
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Courtesy of
: SICK AG
Camera Components used with 3rd party software
: APPLICATION: Print Inspection
: Foil sealed trays
: TECHNOLOGY: Hi res 2D camera
: Diffuse LED illumination, Operator HMI
: METHODOLOGY: Front lighted image,
: complex pattern matching software.
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Courtesy of
Missing Label
Extra Print
Misregistration
Blob
Damaged
Smudge
: SICK AG
Camera Components
: APPLICATION: Parcel Sortation ( & dimensioning)
: freight logistics
: TECHNOLOGY: Line scan camera
: Fixed LED line illumination tracked to moving objects.
: METHODOLOGY: Image software in both the Camera and
attached PC.
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Courtesy of
: SICK AG
When to use 3D?
: 3D using
: structured light?,
: Stereoscopic?,
: triangulation?
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: SICK AG
Camera Components integrated to Machine controls
: APPLICATION: Robotic Bin Picking
: metal parts
: TECHNOLOGY: “scanning” 3D camera
: Moving laser line illumination.
: METHODOLOGY: Image software
compatible with standard CAD files and
Robot coordinate systems.
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: Thank you for your attention.
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